1

▪ Rajapalayam Mills Ltd▪ Sudarshan Spinning Mills▪ Sri Vishnu Shankar Mill Ltd▪ Rajapalayam Spin text▪ Sri Ramco Spinners▪ Rajapalayam Textiles▪ Sandhya Spinning Mills Ltd▪ Thanjavur Spinning Mill Ltd.

TEXTILES

CEMENT PLANTS

• The Ramco cements Limited

SOFTWARE

• Ramco Systems Ltd

FIBRE CEMENT

▪ Ramco Industries Ltd▪ Ramco Lanka (P) Ltd

SURGICAL

•The Ramaraju SurgicalCotton Mills Ltd

Ramco Business Group

th largest cement producer in the country.

Integrated Cement Plants

Grinding & Packing Units

Ramasamy Raja Nagar, Virudhunagar - 1.5 MTPA

Jayanthipuram, Andhra Pradesh - 3.65 MTPA

Alathiyur,

Tamil Nadu 3.05 MTPA

Ariyalur, Tamil Nadu - 5.50 MTPA

Mathodu,

Karnataka - 0.29 MTPA

Uthiramerur,

Kanchipuram – 0.5 MTPA

Valapady,

Tamilnadu - 0.5 MTPA

Kolaghat,

West Bengal -0.95 MTPA

Nagercoil Packing Unit &

Hyderabad Packing Plant.

Vishakhapatnam ,

Andhra Pradesh – 0.5 MTPA

COMPANY PROFILE

- 4200 TPD

- Oct 2008

Line

I - 5000 TPD

- Aug 2011

Line

II

➢ The Ramco Cements Ltd Ariyalur has two Production lines of

capacity & commissioning month details given as follows.

Plant Details

Captive Power plant

- 20 MW

- 40 MW

- 6 MW

Turbine

3 Nos of 20 MW

-each 85 TPH

Steam Capacity

Boiler

The Products manufactured are Ordinary Portland Cement as per BIS & SLSstandards, Portland Pozzolana Cement as per BIS.

Bulk Solid analyzers for quality control at the raw materials stage itself &Modern X-ray - XRD & XRF for analyzing elementary and chemicalcomposition.

State of the art grinding Technology with auto Packer truck loadingarrangement

India’s first aluminum dome for LS & Large additive & fuel storage sheds

COMPANY PROFILE

Global Norms/Standards

8

Reference:

National Benchmark :PAT Consultation Document

International Benchmark :8th NCB International Seminar 2003

Reference:

National Benchmark :PAT Consultation Document

International Benchmark :8th NCB International Seminar 2003

Road Map To Achieve Benchmark

9

Implemented ISO 50001

Energy management organization in the plant

• Through EnMS we are following the Monitoring Reports IER , DEPTS, EMAP Regularly & discussed in monthly Review meeting

• 10 Cross functional ENCON Teams has actively participated in Implementing Energy Conservation activities & Executed Projects successfully.

12

Energy Cell Discussion

Thermal Specific Energy Consumption

14

650

670

690

710

730

2013-14 2014-15 2015-16 2016-17 2017-18

710714

688 685682

Kcal /

Kg C

lin

ker

Electrical Specific Energy Consumption

15

74

76

78

80

82

84

2013-14 2014-15 2015-16 2016-17 2017-18

82.61

77.8477.46 77.15

77.44

Kw

h /

MT

of

Cem

en

t

OPC SHARE (%)

0

25

50

75

100

2016-17 2017-18

4852

Electrical Specific Energy Consumption

16

90.66 88.582.44 82.89 81.63

76.61 73.88 72.09 72.04 72.92

0

35

70

2013-14 2014-15 2015-16 2016-17 2017-18

OPC PPC

Kw

h /

MT

of

Cem

ent

No. of Projects Completed 39 Nos

Cost savings achieved

Rs. 1026.5 Lakhs

Electrical energy saved

148.Lakh Kwh

Thermal Energy saved

1206 mkcal i.e. 201 MT

of coal

Projects with NIL investment

21 Nos.

Investment made RS

382.8Lakhs

Energy Conservation Projects Implemented

for 2015-16 ,2016-17 & 2017-18

17

PAT performance

➢ We are in PAT cycle – II for which the period is 2016-2019.

➢ PAT target given is 0.0719 MToE

➢ In 2019 we will be carrying out our Measurement and

Verification audit along with BEE officials

Renewable Energy & RPO

➢ We have planned in increase the capacity of Solar

energy by 10 kW a year in the following locations

❖ Factory service buildings

❖ Colony residential buildings and

❖ In Mines locations.

➢ RPO - Renewable purchase Obligation - not

applicable to us.

Project Title & Description Status Remarks

Compressor optimization : Presently in line-2 Pre clinker section 3 num 75 kW compressors (4 num 75 kW Compressors occasionally based on requirement) is in operation, similar to Line-1 pre clinker section it is proposed to install 200 kW Compressor with VFD at Line-2. Presently 200 kW compressor with VFD from packing plant can be use for trial purpose.

Completed

Air leak attended 2 Comp running/

Avg 800 kwh to 950 kWh, per day savings based compressor usage.

Air Slide Blower optimization: Line-1 Raw mill Air slide blower has been connected in common header now and two blowers 130AB01A and 130AB03 can be removed as the air requirement is sufficient with existing blowers having standby provision

Completed140 kWh saved on 24 hr RM-1 running.

Street light LED retrofit: Replacement of HPSV 250/150W street light with low power 70/40W LED fittings - 50 Nos in first phase.

Completed

15 Nos 40 W LED Fitting replaced -20 kwh per day saved

Generator frequency optimisation: The Generation frequency at 50.5 can be suitably lowered considering operating condition up to 49.6 Hz and Power reduction can be monitored.

Completed

Avg 300 kW to 350 kW reduction in total load(25MW) observed

Compressor optimisation: Derating of Mixing hopper compressor from 45 kW to 30 kw – to minimize the idle hours & stopping the compressor 20min after weigh feeder stoppage

Completed 380 kwh/day saved

Mandatory audits, opportunitiesidentified (vs) initiatives completed

Project Title & Description Status Remarks

Bag filter fan optimization: Dedusting bag filter 150FN04 installed in 150BC02 head end is running even if 150BC02 in off condition (while unloading at open yard). Its installed & operating power is 30 kW and 25 kW respectively, It is proposed to stop the conveyor during open yard unloading. Expected power savings: 25 kW/hr.

Completed240 kwh /Day savings measured

Bag filter fan optimization: Dedusting bag filter 150FN01 installed in 150BC01 head end stops one hour after stopping its 150BC01 conveyor, As per site condition & in consultation with user dept it is sufficient to run the bag filter just 10 minutes after stopping the conveyor, Its installed & operating power is 55 kW & 30 kW respectively, Expected power saving:25kWh/150BC01 stoppage.

Completed120 kwh /Day savings measured

Belt conveyor optimization : Coal unloading Belt conveyors 150BC01,02&03 transport coal in variable TPH based on Wagon/Truck unloading method -Unloading TPH measured around 600-750 TPH for Wagon and 200-380 TPH for Truck, As the operating load varies Smart Delta-Star Drive/convertor on trial basis is proposed on one conveyor, the controller operates motor in star mode at lower TPH and changes to Delta mode at higher TPH. Expected power savings: 10-20%.

Completed

5-7 kW average power reduction measured. At 250-350 TPH unloading.

For 10 hour operation 70 kwh saved.

Project Title & DescriptionStatus /

Target DateRemarks

Operate drinking water pumps with flow based control valve

CompletedHigh level switch installed,Savings measured up to 300 kwh per day.

Line-1 Optimize nose ring fan power consumption by avoiding throttling loss

CompletedVFD installed and measuredpower savings to be done.

Reducing false air in Down comer CompletedLeakages has identified & same was arrested. Now false air level is 8%.

Optimize coal mill fan (Line 2) power consumption by reducing false air ingress

CompletedMill inlet RAV replaced and false air 17% under observation

Replace 40 MW ACC fans with energy-efficient fans Completed

ACC fins cleaning completed for 40 & 20 MW and found satisfactory, further modification not required due to low load factor.

Optimize unloading power of ash & instrument compressors by installing VFD

CompletedInstrument compressor VFD is not advisable in the view of reliability

Project Title & DescriptionStatus /

Target DateRemarks

Waste heat utilization from cooler ventIn Progress/ Feb 2019

In operation in line-1 & Power savings achieved is 0.6 kWh/Ton of material. So similar proposal was in progress for Line-2.

Replace auxiliary cooling water pump with suitable

capacity energy-efficient pumpIn progress Approval raised.

Replace 40 MW boiler feed pump with suitable

capacity energy-efficient pumpIn Progress

PO released, material

expected by Dec 2018

Insulate identified defective & bare hot surface

area to reduce radiation lossIn progress

65 % completed,

Remaining 35% in

progress

S. No Particulars TSR% Year Quantity

1 TPP Ash as fuel(in MT)

1:0.6 (Coal)

15-16 18534

16-17 21416

17-18 18269

2 Tyre Oil(in MT)

1:1 (Diesel)

15-16 77.9

16-17 60.7

17-18 67.9

Alternate Fuel Utilisation

10/23/2018 RCL – Govindapuram, Ariyalur 2525

➢Cooler Hot Gas From Cooler 1 to Raw mill-1 Project Has been Commissioned.

➢Overall the benefit is around 15 TPH increase in Mill Feed Rate & 0.6 kwh/T of

Sp. Power savings Achieved

➢The following are the raw mill operating condition with the Feed moisture of 10.5%

Description UOMWith Booster Fan Without Booster Fan

Coal mill ON Coal mill OFF Coal mill ON Coal mill OFF

Mill feed Rate TPH 330-340 335-340 305-315 325-330

Mill Power KW 1800-2300 1800-2100 1700-2200 1800-2300

Mill Fan Power KW 2080-2150 2000-2150 2000-2150 2050-2150

BH Fan Power KW 450-480 500-520 340-370 410-440

Mill Inlet Temp DEGC 250-275 270-285 235-255 245-270

Mill Outlet Temp DEGC 68-73 68-70 60-68 65-75

Mill Inlet Draft1 MMWG -50 TO -90 -50 TO -70 -80 TO -130 -70 TO -100

Mill Differential

Pressure MMWG60-70 70-75 60-68 65-75

Specific power Kwh/Ton 13.30 13.95

Riplicability of the idea implemented

National Award for

Environmental Excellence

Five Star Rating for

Pudhupalayam Mines by IBM

Green Product National Award for Excellence in energy management 2016&17 by CII

Industries Safety Award and

Excelling workmen Award

Out of our Many projects done so far , We are happy to

present some of our Projects in detail as listed bellow

feed gate

(air lock)

mill casing

water

injection

dam ring

louvre ring

nozzle of

material scraper

mill outlet duct

speed reducer with

table bearingand motor

clutch

grinding table

hot gas inlet

hydraulic cylinder

table liner

roller with tyre

or segments

roller axle

rocker arm

discharge flap

separator

tailings cone

separator

guide vanes

cage rotor

separator

product discharge

mill exhaust

➢ The original seal for Rocker arm (Belt Covered) was frequently getting

damaged, which leads to false air entry

➢ Initially the seal is replaced with graphite rope seal & the false air been

arrested in 2 sides by tightening the bolt over the graphite rope. But at

the Top and bottom of roller the seal remains as earlier which cannot

restrict the false air because of rocker arm movement.

➢ With the new type of Seal, false air is restricted at all sides by the cloth.

Also the leakages at Rotary airlock has been arrested and resulted in

the reduction of false air across the mill by 5% and which implicates the

power savings on the raw mill fan by 50kw

PROJECT DESCRIPTION:

Original Seal with Belt.

Graphite Rope Seal

with adjustable

bolts.

AS PER DESIGN: INITIAL MODIFICATION

Cloth type seal which covers all around

the roller

AT PRESENT

➢ Tangible benefit

➢ 50 Kw Savings in Mill Fan Power & Cost Savings

14.3 Lacs/Annum

➢ Intangible benefit

➢ Easy to identify any leakage in the seal due to cloth

damage

➢ Easy to patch up or change the cloth.

BENEFITS ACHIEVED:

feed gate

(air lock)

mill casing

water

injection

dam ring

louvre ring

nozzle of

material scraper

mill outlet duct

speed reducer with

table bearingand motor

clutch

grinding table

hot gas inlet

hydraulic cylinder

table liner

roller with tyre

or segments

roller axle

rocker arm

discharge flap

separator

tailings cone

separator

guide vanes

cage rotor

separator

product discharge

mill exhaust

SAVINGS CALCULATION:

Description UnitValue

Before After

Measured false air across Raw mill % 25 20

Measured input power consumption of mill fan kW 2250 2200

Measured airflow m3/s 160 150

Power savings kW 50

Annual operating hours Hours 7260

Annual electricity savings kWh 363000

Electricity cost Rs/kWh 3.94

Annual cost savings Rs lacs 14.3

➢ As per OEM the coal mill water spray is fixed near all rollers as the

water will be poured from a 1/2’’pipe to the grinding track.

➢ The following problem has been faced in the mill operation

➢ Coating on roller and table - due to excess & uneven water flow

➢ Less Water contribution for grinding

➢ More Mill maindrive power consumption

➢ Mill vibration and instability in operation.

➢ Then the water spray arrangement has been modified as slotted type

nozzle injection which can distribute water utilization more in the

grinding track

PROJECT DESCRIPTION:

water spray with simple

pipe arrangement

water spray with slotted

pipe arrangement

AS PER DESIGN: AT PRESENT

➢ Tangible benefit

➢ 30 Kw Savings in Mill maindrive Power & Cost

Savings 6.0 Lacs/Annum

➢ Intangible benefit

➢ Less vibration in mill operation reduce the risk in

mill reliability and maintenance spends.

➢ Less water consumption leads to less hot gas for

mill operation and helps more hot gas availability

for raw mill operation

BENEFITS ACHIEVED:

SAVINGS CALCULATION:

Operating parameters Unit Before After

Mill Output TPH 28-30 28-30

Mill Maindrive Power consumption kW 450-480 420-450

Mill outlet Temperature Deg C 65-70 65-70

Mill Water Spray Flow m3/hr 4-4.5 3-3.5

Mill Vibration mm/sec 0.9-1.5 0.6-0.8

Savings in mill Maindrive power consumption kW 30

Annual operating hours Hours 4950

annual electricity savings kWh 152285

Electricity cost Rs/kWh 3.94

annual cost savings Rs lacs 6.1

➢ Tangible benefit– Electrical Savings Upto 4 kwh/T of Cement

➢ Intangible benefit – Ball mill will be run Based on the Demand & less

Maintenance for the Equipment.

PROJECT DESCRIPTION:

➢ We have Roller Press with Ball mill Combi-Grinding Circuit for Clinker

Grinding in original.

➢ We have taken a trial on running OPC with Finished mode i.e. we run

only roller press circuit and ball mill not in operation. In finished mode,

the Sp. Power is comparatively lower than the Combi-mode grinding

but the Output Rate is Less than the Combi mode Grinding.

BENEFITS:

Hot gas

Ball Mill Reject Elevator

Roller Press

Reject Elevator

Separator

Bag house

Material FeedBall Mill

Roller Press

Final Output

(Cement)

To Chimney

We have

Bypassed the

Ball mill

circuit by

finished mode grinding.

➢ Initially we have designed 45 KW Compressor in mixing hopper

air blaster applications.

➢ Through the air requirement of the blasters during both plant

running is observed and arrested the leakages in compressor

air line, air blasters and solenoid valves.

➢ Monitored the compressors run hrs and observed that the

Loading hrs was lesser than the Unloading hrs.

➢ Then we have taken trial by running 30 KW compressor instead

of 45 kW & there was no problem in air blasters Operation

COMPRESSED AIR OPTIMIZATIONCOMPRESSED AIR OPTIMIZATION

INSTALLING LOW CAPACITY COMPRESSOR IN MIXING HOPPER

COMPARISON OF POWER CONSUMPTIONCOMPARISON OF POWER CONSUMPTION

COMPRESSED AIR OPTIMIZATIONCOMPRESSED AIR OPTIMIZATION

➢ Before implementation, the power taken

by 45 KW compressor = 981 units

➢ After optimization of air usage, the power taken by 30 KW

compressor = 587 units

Saving of electricity= 394 units/ day

Annual saving of electricity is 143810 units

1 unit of electricity = Rs.4

Annual Savings = Rs.5,75,240

POWER SAVINGPOWER SAVING

➢ In Line-II Pre-clinkerization, we were using 3 nos of 75KW

compressors for plant operation. (Raw mill, coal mill & Kiln)

➢ Free air Delivery of all compressors has been checked & air

leakages were identified during the compressed air audit.

➢ The Issues were fixed in the plant shutdown & based on the

Loading pattern the compressor operation has been carried

out.

➢ At present only 2 75kw compressors in operation for

Preclinkerisation section in Line-II

COMPRESSED AIR OPTIMIZATIONCOMPRESSED AIR OPTIMIZATION

ELIMINATION OF ONE 75 KW COMPRESSOR IN LINE-2

AIR LEAKAGE PERCENTAGEAIR LEAKAGE PERCENTAGE

COMPARISON OF POWER CONSUMPTIONCOMPARISON OF POWER CONSUMPTION

➢ Before implementation, the power taken by E75 (3 Nos)

compressor for pre clinkeration II = 5440 units

➢ After optimization of air usage, the power taken by E75

(2 Nos) compressors for pre clinkeration II = 3225 units

Saving of electricity= 2215 units/ day

Annual saving of electricity is 808475 units

Annually savings =Rs 3233900 (Rs 4/unit)

POWER SAVINGSPOWER SAVINGS

• Two billion people in the world do not have electricity

• Average consumption of a person is 10,000 kWh of electricity a

year.

• The average household emits 10,000 kgs of CO2 annually.

• Once the fossil fuels have been used up there will be no more to

replace them

• The average temperature of the Earth is Raising due to global

warming.

• The % of CO2 in the air is increased by 0.5% in a Decade.

• The increase in temperature will speed up the melting of the polar

ice caps

• Extremes of weather will Cause Disaster

Importance to Conserve Energy

Understand your energy needs, Investigate options for energy conservation and

efficiency

Much has been done, but much

more can be done